25 Critical Issues with the ProcessCasting Speed & Pattern EntrapmentPore-type Defect- Found on all fracture surfacesSize variation between 400 and1500 µmFilm-type DefectFound only where non-planar metalfronts were observedSize variation between 1 and 4.5 mm

31 Process Summary & ConclusionsHandtmann scrap levels ≈ 10%BMW reverting to gravity and pressure die casting for aluminium heads and blocks.Honda retaining die casting processes for their aluminium components.“Lost foam casting is on the decline at General Motors because the relatively low ultimate strength of aluminum cast in unbonded sand is not up to the high demand of current and future engine designs.”